Engineering a Next-Generation Smart Controller for Industrial Heating Systems

From Legacy Interface to Intelligent Embedded Platform

A global manufacturer of induction heating equipment approached BWC Labs with a clear objective: modernize their machine interface while preserving the reliability and robustness their customers depend on.

Their existing standalone controllers were functional, but they limited scalability, operator efficiency, and future feature expansion. The client needed more than a UI refresh they needed a fully integrated embedded control platform that combined hardware innovation with intelligent firmware design.

BWC Labs delivered exactly that.

The Engineering Challenge

The engagement required rethinking the controller architecture across both hardware and software dimensions:

  • Replace legacy standalone controllers with a modern, touchscreen-based pendant system
  • Enable recipe-driven machine configuration to improve process consistency
  • Provide real-time operational feedback for improved control and visibility
  • Expand onboard memory to support advanced recipe management
  • Integrate a safety-compliant emergency stop (e-stop) circuit within the controller architecture
  • Ensure reliability suitable for demanding industrial heating environments

This required tight coordination between electrical design, firmware development, safety engineering, and user experience design.

BWC’s Embedded Engineering Approach

As part of our Embedded Systems practice, BWC Labs took complete ownership of the product development lifecycle:

  • Architecture Redesign : Unified architecture across multiple products, simplifying development and maintenance.
  • Hardware Rework : Redesigned key hardware modules to enhance sensor integration and response efficiency.
  • Logic Development : Rewrote embedded logic to optimize sensor communication and control flow.
  • Code Standardization: Streamlined the codebase for easier versioning, reusability, and future scalability.

The customer needed a partner who could understand both hardware and software, and bring structure back to the embedded ecosystem.

1. System Architecture & Requirements Engineering

We collaborated with the client’s product team to define functional, safety, and performance requirements. The solution architecture was designed to support future scalability while maintaining deterministic performance.

2. Custom Hardware Development

  • Designed dedicated interface and display boards
  • Executed full PCB design and assembly
  • Integrated safety circuitry including e-stop
  • Ensured compliance-ready electrical design

“Improving the heartbeat of the system that’s what this project achieved. The new embedded architecture not only runs faster but empowers engineers to innovate confidently”

– Quote

Get Started

Let’s Build Something Great

Partner with seasoned experts to accelerate your digital transformation and engineering workflows across industries with cutting-edge solutions.